Electrical conductor with standoff means

ABSTRACT

An improved electrical conductor of the type having spaced, oblique louvers resiliently mounted on a pair of spaced strips and adapted for making bridging electrical contact between a pair of electrically conducting terminals, such as a pair of currentcarrying buss bars, having means for drawing the same together. Means coupled with the conductor is provided for determining the minimum distance between the terminals. In a preferred embodiment, the conductor is circular in configuration and the louvers are radially disposed. One form of the determining means includes a pair of continuous inner and outer peripheral flanges integral with the body of the conductor, the flange width being less than the latterally projected width of the louvers. In another form of such means, a pair of spacers are provided for the inner and outer peripheries of the conductor, the spacers being either separate from or attached to the conductor body.

United States Patent [191 Deal [ Jan. 21, 1975 ELECTRICAL CONDUCTOR WITHSTANDOFF MEANS Robert S. Deal, Mountain View, Calif.

[73] Assignee: Multilam Corporation, Los Altos,

Calif.

22 Filed: Jan. 15, 1973 21 Appl. No.: 323,611

[75] Inventor:

[52] US. Cl 339/95 R, 151/35, 174/94 S [51] Int. Cl H01r 7/08 [58] Fieldof Search 339/95; 151/35; 174/84 S,

[56] References Cited UNITED STATES PATENTS 728,092 5/1903 Edwards339/95 A 2,012,032 8/1935 Zinnbauer 151/35 2,256,851 9/1941 Schnorr151/35 2,321,155 6/1943 Poupitch 151/35 2,666,468 1/1954 Poupitch 151/3558 28' J il 4 m Primary ExaminerJoseph H. McGlynn [57] ABSTRACT Animproved electrical conductor of the type having spaced, oblique louversresiliently mounted on a pair of spaced strips and adapted for makingbridging electrical contact between a pair of electrically conductingterminals, such as a pair of current-carrying buss bars, having meansfor drawing the same together. Means coupled with the conductor isprovided for determining the minimum distance between the terminals. Ina preferred embodiment, the conductor is circular in configuration andthe louvers are radially disposed. One form of the determining meansincludes a pair of continuous inner and outer peripheral flangesintegral with the body of the conductor, the flange width being lessthan the latterally projected width of the louvers. In another form ofsuch means, a pair of spacers are provided for the inner and outerperipheries of the conductor, the spacers being either separate from orattached to the conductor body.

9 Claims, 6 Drawing Figures ELECTRICAL CONDUCTOR WITH STANDOFF MEANSThis invention relates to improvements in the making of electricalconnections between a pair of currentcarrying devices and, moreparticularly, to an electrical conductor for placement between a pair ofseparable electrical terminals to enhance the electrical contacttherebetween.

BACKGROUND OF THE INVENTION In US. Pat. No. 3,453,587, a tubularelectrical connector is disclosed wherein a plurality of generallyparallel vanes or louvers are integral with and are resilientlyconnected in angled relationship to a pair of spaced, circular strips.The connector is constructed so that it can be inserted into the sleeveof a connector of the type utilizing a jack receivable within thesleeve. Generally, the plug will be dimensioned such that, when it isinserted in the sleeve, it will engage the louvers and compress thesame, yet the louvers will also make electrical contact with the sleeve.Thus, the louvers assure that intimate electrical contact is madebetween the sleeve and the plug. When the plug is removed, the louversreturn to their initial positions due to the resilient connectionthereof with the two strips.

Other modifications of the type of connector described include agenerally flat conductor having a plurality of such vanes of louversresiliently secured to a pair of parallel side strips. Such a flatconductor is suitable for use between a pair of terminals having flatworking surfaces in which case, the louvers bridge the working surfacesand enhance the electrical contact therebetween.

Oftentimes, the two terminals are constructed so that they arerelatively shiftable toward and away from each other and areinterconnected by a fastener, such as a screw freely movable through oneof the terminals and threadably connected to the other terminal. Byrotating the screw in one direction, the terminals can be moved towardeach other and into electrical contact with each other. Such contact maybe less than that which is desired because of surface defects of theterminals. Thus, better electrical contact between the terminals shouldbe established to minimize or eliminate energy losses at the terminalsthemselves.

SUMMARY OF THE INVENTION The present invention is directed to aconductor for use with a pair of relatively shiftable electricalterminals of the type having fastener means for drawing the sametogether. To this end, the conductor of this invention is provided witha plurality of spaced, angled, resilient vanes for making electricalcontact with the working surfaces of the terminals and further includesmeans thereon for limiting the distance between the terminals as thelatter are drawn toward each other when the connector is disposedtherebetween. Thus, the limiting means assures that the terminals can bebrought together to provide for the necessary electrical contacttherebetween, yet the louvers of the connector will make the desiredelectrical contact with the working surfaces of the terminals withoutbeing deflected so much as to cause a permanent set in the louvers.

In one embodiment, the invention comprises a circular connector havingradial louvers and generally continuous inner and outer peripheralflanges for engaging the working surfaces of the two terminals as theterminals are drawn together by the fastener means. The flanges,therefore, provide stops which determine the minimum distance betweenthe terminals. Accordingly, the louvers of the connector will be inproper bridging electrical contact with both terminals yet the louverswill be protected against structural damage.

In another embodiment of the invention. the connector is circular andhas radial louvers and further includes generally flat inner and outerperipheral surfaces. An inner spacer engages the inner surface of theconnector and an outer spacer engages the outer pe' ripheral surface ofthe connector. The two spacers have the same thickness and serve toprovide stops to determine the minimum distance between a pair ofterminals when the connector is positioned therebetween. The spacers canbe attached to or separate from the connector.

The connector of this invention can have other configurations, such asrectangular, or the like. The flanges and spacers can be continuous orcomprised of a number of spaced segments. Also, the flanges can bcintegral with the connector itself so that the conductor and the flangescan be formed simultaneously in a suitable manufacturing operation, suchas a stamping process.

Terminals with which the invention is usable can be of any construction,such as flat bars wherein one is stationary and the other movable orboth can be stationary or both movable. lf movable, a terminal can berotatable or can be capable of straight-line movement. The connector ofthis invention can electrically bridge the gap between any twoelectrical conducting devices wherein transfer of electricity isrequired.

The primary object of this invention is to provide an improvedelectrical connector for use with a pair of electrical terminals of thetype having fastener means for drawing the same toward each other,wherein the connector has spaced, angled, resilient louvers and alateral projection adjacent to the louvers so that, when the connectoris disposed between the terminals and the terminals are drawn togetherby the fastener means, the louvers will move into electrical contactwiththe working surfaces of the terminals and the projection means willlimit the travel of the terminals toward each other so as to assure thatthe louvers will not be excessively deflected and thereby damaged.

Another object of this invention is to provide a connector of the typedescribed wherein the connector is circular in configuration and theprojection means comprises inner and outer peripheral flanges on opposedsides of the louvers so that the flanges engage the working surfaces ofthe terminals yet allow the louvers to be deflected sufficiently toassure proper electrical contact between the terminals withoutcompressing the terminals to the extent of causing a permanent settherein.

A further object of this invention is to provide a connector of theaforesaid character wherein the connector is circular in configurationand the projection means comprises inner and outer peripheral spacersfor limiting the distance by which a pair of terminals used with theconnector can be brought together yet allow sufficient electricalcontact between the louvers and the terminals.

Other objects of this invention will become apparent as the followingspecification progresses, reference being had to the accompanyingdrawings for an illustration of the invention.

In the drawings:

FIG. 1 is a side elevational view of a preferred embodiment of theconnector of this invention, only a limited number of louvers beingshown to simplify the figure;

FIG. 2 is an enlarged, cross-sectional view taken along line 22 of FIG.1;

FIG. 3 is an end elevational view of a pair of terminals havingfastening means for drawing the same together, illustrating the use of apair the connectors of the present invention between the working facesof the terminals;

FIG. 4 is a fragmentary, perspective view of the connector showing theinner and outer peripheral standoff flanges thereof;

FIG. 5 is a view similar to FIG. 1 but showing another form of theconnector; and

FIG. 6 is an enlarged, cross-sectional view taken along line 6--6 ofFIG. 5.

A preferred embodiment of the connector of this invention is broadlydenoted by the numeral 10 and comprises a body 12 of metal, such asberyllium copper or the like. Body 12 is circular in configuration andhas a central hole 14 therethrough formed by a continuous innerperipheral flange 16 integral with a first circular strip 18 (FIG. 2),the latter being integral with a second circular strip 20 but in adifferent plane therefrom.

Body 12 further includes a third circular strip 22 spaced outwardly andsurrounding strip 20 and a fourth circular strip 24 integral with strip22 and having a diameter greater than the diameter of strip 22. Strips18 and 20 form a first pair of interconnected, circular, concentricstrips, and strips 22 and 24 form a second pair of interconnected,circular, concentric strips surrounding the first strips 18 and 20. Asshown in FIG. 2, strips 20 and 22 are in a first plane and strips 18 and24 are in a second plane substantially parallel with the first plane. Acontinuous outer peripheral flange 26 is integral with strip 24 and isconcentric with and of the same width as flange 16.

Body 12 has a plurality of electrically conducting, angled louvers 28which span the distance between and are integral with strips 20 and 22.Each louver 28 has a pair of opposed terminal-engaging side margins 30and 32 (FIG. 2) and is resiliently mounted on strips 20 and 22 so thatthe louver can be deflected or rotated about its central axis 34 whenside margins 30 and 32 engage working surfaces of a pair of terminals 36and 38 in a manner to be described. Louvers 28 are, therefore,substantially radial with respect to the central axis 40 (FIG. 1) ofbody 12 and the louvers surround axis 40 although FIG. 1 merely shows alimited number of louvers, the concentric dashed lines 42 and 44representing the end boundaries of omitted louvers to simplify FIG. 1.

Flanges 16 and 26 are substantially symmetrical with respect to centerline 34 of each louver 28. Moreover, side margins 30 and 32 of eachlouver 28 projects outwardly a distance from center line 34 greater thanthe distance by which flanges l6 and 26 project outwardly from suchcenter line. This is illustrated in FIG. 2, the flanges being shown withflat side faces 46 and 48 at one side of body 12.

Terminals 36 and 38 can be of any construction, such as a pair of platesor buss bars. The terminals are interconnected by a pair of spacedfasteners 50 and 52, with each fastener comprising a machine screwhaving a head 54 and a threaded shank to which a nut 56 is coupled. Theterminals are adapted to be moved toward each other when the nuts arerotated in one direction on the shanks.

For purposes of illustration, a pair of connectors 10 are shown betweenthe flat working faces 58 and 60 (FIG. 3) of terminals 36 and 38,respectively. The shanks of fasteners 50 and 52 extend through thecentral holes 14 of the two connectors. FIG. 3 illustrates the operativepositions of terminals 36 and 38 with connectors 10 therebetween. Insuch operating condition, the curved side margins 30 and 32 of louvers28 of each connector 10, make electrical contact with working surfaces58 and 60. Moreover, side faces 46 and 48 of flanges 16 and 26 engageworking surface 58 of terminal 36; whereas, the outer flat faces of sidestrips 18 and 24 engage working surface 60 of terminal 38. Thus, flangesl6 and 26 of each connector 10 define standoff means limiting the travelof terminals 36 and 38 toward each other as nuts .56 are tightened ontothe shanks of fasteners 50 and 52. Thus, the flanges determine theminimum distance by which terminals 36 and 38 are separated from eachother so that louvers 28 are not excessively deflected through adistance which would otherwise cause structural damage thereto andprovide a permanent set in the louvers. Since the louvers porjectlaterally from body 12 a greater distance than flanges 16 and 26, properelectrical contact between the louvers and terminals 36 and 38 isassured even though flanges l6 and 26 provide stops for preventingfurther movement of terminals 36 and 38 toward each other after apredetermined minimum distance has been reached between the terminals.This minimum distance, determined by the width of flanges l6 and 26, isselected to assure the proper contact between the louvers and theterminals, yet permits the louvers to return to their original, unsprungpositions when the terminals are separated from each other.

While body 12 has been shown as being circular in configuration, it canhave other configurations as well. For instance, it can be rectangular.Also, it can be formed in a suitable stamping process to minimizeproduction costs. In such a stamping process, flanges l6 and 26 areformed simultaneously with the formation of the other parts of body 12.Also, flanges l6 and 26 need not necessarily be continuous. They can beformed of spaced flange segments if desired, only criterion being thatthey serve to limit the movement of terminals 36 and 38 toward eachother as they are drawn together by fasteners 50 and 52.

While only a sigle annular group of louvers has been shown, two or moresuch annular groups in concentric relationship could be provided forbody 12. In each group, the louvers would be resiliently mounted toadjacent, annular bands surrounding the central axis of body 12 and thelouvers would essentially be radial with respect to the central axis.

A feature of the present invention is that the resiliency of the louversof body 12 compensates for expansion and contraction of the terminalswith which the invention is used even though the terminals are ofdifferent metals. For instance, one of the terminals could be of copperand the other of aluminum. Thus, even if one terminal expands orcontracts differently from the other terminal, the louvers will bemaintained in good electrical contact at all times, thus assuringmaximum energy transfer between the terminals notwithstanding theirdissimilarities. The resiliency of the louvers also assures goodelectrical contact without the need for large torques. Furthermore, thelouvers can be of different configurations, such as straight or curvedto form an 5" configuration. Also, the louvers can have sharp edges soas to scrape adjacent terminals surfaces, thus maintaining the properelectrical contact at all times.

Another form of the invention is illustrated in FIGS. 5 and 6 andcomprise a connector assembly 70 having a body 72 of metal, the bodybeing substantially of the same construction as that of body 12 (FIGS.1-4) except that body 72 does not have flanges l6 and 26 thereon. Tothis end, body 72 includes a plurality of spaced, radially disposedlouvers 74 which are angled with respect to the plane of the body asshown in FIG. 6. Body 72 includes an inner peripheral strip 76 and anouter peripheral strip 78, louvers 74 spanning the distance between andbeing resiliently mounted on and integral with strips 76 and 78. Theinner periphery of strip 76 defines an opening 80 into which a firstspacer 82 is received. The spacer has a stepped cross section in themanner shown in FIG. 6 so that it can support strip 76 when spacer 82extends into opening 80. For purposes of illustration, spacer 82 has acentral opening 84.

An outer, annular spacer 86 is provided for supporting strip 78. To thisend, spacer 86 has a stepped cross section as shown in FIG. 6, it beingclear that strips 76 and 78 are flat as are the strip-engaging surfacesof the stepped portions of spacers 82 and 86.

Spacers 82 and 86 have flat, outer surfaces and are of the samethickness, namely, a thickness greater than the thickness of strips 76and 78 but less than the normal lateral projected width of louvers 74 asshown in FIG. 6. Thus, when a pair of terminals 88 and 90 are broughttogether, louvers 74 engage the inner surfaces of the terminals and aredeflected until the flat, outer surfaces of spacers 82 and 86 engage theterminals. At this point, the louvers are not compressed to the extentthat they are permanently deformed. Thus, when the terminals areseparated from each other, the louvers will return to their normal,equilibrium positions as shown in FIG. 6.

The outer surfaces of spacers 82 and 86 can have other configurations ifsuch are desirable. It is only necessary that they be operable toprovide the necessary stops for preventing further movement of terminals88 and 90 toward each other after the separation of the terminals hasreached a minimum value.

I claim:

1. An electrical conductor comprising a circular body of electriallyconducting material, said body having a central hole therethrough, afirst pair of circular strips surrounding the hole, a second pair ofcircular strips surrounding and being spaced from the first pair ofstrips, each pair of strips including an inner strip and an outer strip,and a plurality of louvers spanning the distance between the first andsecond pairs of strips, the louvers being at acute angles relative tosaid strip pairs and being substantially radial to the central axis ofthe hole; a continuous lateral flange integral with-the inner strip ofthe first pair, whereby the flange surrounds the hole; and a secondflange integral with the outer strip of the second pair, the inner stripof the first pair and the outer strip of the second pair being in afirst plane, the outer strip of the first pair and the inner strip ofthe second pair being in a second plane parallel to the first plane,each louver projecting outwardly in opposed directions from the secondplane through a predetermined distance, the width of each flange beingless than two times the distance, whereby the louvers will engage theworking surfaces of a pair of terminals when the connector is disposedtherebetween before the flanges engage said working faces.

2. An electrical conductor comprising: a circular body of electricallyconducting material, said body having a central hole therethrough, afirst annular strip surrounding the hole and a second annular stripspaced from and surrounding the first strip, and a plurality of louversspanning the distance between the first and second strips, the stripsbeing flat and substantially coplanar, the louvers being at acute anglesrelative to said strips and being substantially radial to the centralaxis of the hole; and a pair of spacers, one of the spacers beingprovided for the inner periphery of the body and the other spacer beingprovided for the outer periphery thereof, each spacer having an annularstepped portion engageable with a respective strip, said one spacerextending through said central hole, each spacer having a pair ofopposed, generally flat, outer, terminalengaging surfaces with thedistance between said outer surfaces of each spacer being less than thenormal projected distance of the louvers laterally of the plane of thestrips.

3. An electrical conductor comprising: a body having a circularconfiguration, a central hole therethrough, and being formed ofelectrically conducting material, said body having a pair of spacedstrips and a number of spaced, electrically conducting louversresiliently mounted on the strips and extending at an acute angle withrespect thereto, said body adapted to be disposed between a pair ofelectrically conducting terminals movable toward and away from eachother with the louvers being engageable with the terminals; and an innerperipheral flange and an outer peripheral flange, said flanges beingcoupled with the body and projecting laterally therefrom with the innerflange surrounding said hole and the outer flange surrounding said innerflange, the flanges being operable for limiting the movement of theterminals toward each other when the connector is disposed therebetween.

4. A connector as set forth in claim 3, wherein said flanges arecontinuous and are provided with respective flat, outerterminals-engaging faces at one side of the body.

5. A connector as set forth in claim 3, wherein the body includes a pairof spaced, concentric strips, the louvers being integral with andspanning the distance between the strips, said flanges being integralwith the strips in spaced relationship to respective ends of thelouvers.

6. An electrical conductor comprising: a body of electrically conductingmaterial, said body having a first pair of interconnected, circularstrips and a second pair of interconnected, circular strips surroundingthe first strips, one of the strips of each pair having a diametergreater than that of the other, adjacent strip; a number of spaced,electrically conducting louvers being resiliently mounted on, integralwith and spanning the distance between the outer strip of the first pairand the inner strip of the second pair, the louvers extending at anacute angle with respect to the strips, the outer strip of the secondpair being coplanar with the inner strip of the first pair and the innerstrip of the second pair being coplanar with the outer strip of thefirst pair, said body adapted to be disposed between a pair ofelectrically conducting terminals movable toward and away from eachother with the louvers being engageable with the terminals; and meanscoupled with the body and projecting laterally therefrom for limitingthe movement of the terminals toward each other when the connector isdisposed therebetween.

7. An electrical conductor comprising; a body of electrically conductingmaterial, said body having a pair of spaced strips and a number ofspaced, electrically conducting louvers resiliently mounted on thestrips and extending at an acute angle with respect thereto, said bodyadapted to be disposed between a pair of electrically conductingterminals movable toward and away from eachother with the louvers beingengageable with the terminals; and a pair of spacers coupled with thebody and projecting laterally therefrom for limiting the movement of theterminals toward each other when the connector is disposed therebetween,one of the spacers being at the inner periphery of said body and theother spacer being at the outer periphery of the body, each spacerhaving a thickness greater than that of said strips but less than thenormal projected distance of the louvers laterally of the strips, eachspacer having a stepped portion engageable with a respective strip.

8. A connector as set forth in claim 7, wherein said spacers areconnected to respective strips.

9. A connector as set forth in claim 7, wherein the spacers areseparable from respective strips.

1. An electrical conductor comprising a circular body of electriallyconducting material, said body having a central hole therethrough, afirst pair of circular strips surrounding the hole, a second pair ofcircular strips surrounding and being spaced from the first pair ofstrips, each pair of strips including an inner strip and an outer strip,and a plurality of louvers spanning the distance between the first andsecond pairs of strips, the louvers being at acute angles relative tosaid strip pairs and being substantially radial to the central axis ofthe hole; a continuous lateral flange integral with the inner strip ofthe first pair, whereby the flange surrounds the hole; and a secondflange integral with the outer strip of the second pair, the inner stripof the first pair and the outer strip of the second pair being in afirst plane, the outer strip of the first pair and the inner strip ofthe second pair being in a second plane parallel to the first plane,each louver projecting outwardly in opposed directions from the secondplane through a predetermined distance, the width of each flange beingless than two times the distance, whereby the louvers will engage theworking surfaces of a pair of terminals when the connector is disposedtherebetween before the flanges engage said working faces.
 2. Anelectrical conductor comprising: a circular body of electricallyconducting material, said body having a central hole therethrough, afirst annular strip surrounding the hole and a second annular stripspaced from and surrounding the first strip, and a plurality of louversspanning the distance between the first and second strips, the stripsbeing flat and substantially coplanar, the louvers being at acute anglesrelative to said strips and being substantially radial to the centralaxis of the hole; and a pair of spacers, one of the spacers beingprovided for the inner periphery of the body and the other spacer beingprovided for the outer periphery thereof, each spacer having an annularstepped portion engageable with a respective strip, said one spacerextending through said central hole, each spacer having a pair ofopposed, generally flat, outer, terminal-engaging surfaces with thedistance between said outer surfaces of each spacer being less than thenormal projected distance of the louvers laterally of the plane of thestrips.
 3. An electrical conductor comprising: a body having a circularconfiguration, a central hole therethrough, and being formed ofelectrically conducting material, said body having a pair of spacedstrips and a number of spaced, electrically conducting louversresiliently mounted on the strips and extending at an acute angle withrespect thereto, said body adapted to be disposed between a pair ofelectrically conducting terminals movable toward and away from eachother with the louvers being engageable with the terminals; and an innerperipheral flange and an outer peripheral flange, said flanges beingcoupled with the body and projecting laterally therefrom with the innerflange surrounding said hole and the outer flange surrounding said innerflange, the flanges being operable for limiting the movement of theterminals toward each other when the connector is disposed therebetween.4. A connector as set forth in claim 3, wherein said flanges arecontinuous and are provided with respective flat, outerterminals-engaging faces at one side of the body.
 5. A connector as setforth in claim 3, wherein the body includes a pair of spaced, concentricstrips, the louvers being integral with and spanning the distancebetween the strips, said flanges being integral with the strips inspaced relationship to respective ends of the louvers.
 6. An electricalconductor comprising: a body of electrically conducting material, saidbody having a first pair of interconnected, circular strips and a secondpair of interconnected, circular strips surrounding the first strips,one of the strips of each pair having a diameter greater than that ofthe other, adjacent strip; a number of spaced, electrically conductinglouvers being resiliently mounted on, integral with and spanning thedistance between the outer strip of the first pair and the inner stripof the second pair, the louvers extending at an acute angle with respectto the strips, the outer strip of the second pair being coplanar withthe inner strip of the first pair and the inner strip of the second pairbeing coplanar with the outer strip of the first pair, said body adaptedto be disposed between a pair of electrically conducting terminalsmovable toward and away from each other with the louvers beingengageable with the terminals; and means coupled with the body andprojecting laterally therefrom for limiting the movement of theterminals toward each other when the connector is disposed therebetween.7. An electrical conductor comprising; a body of electrically conductingmaterial, said body having a pair of spaced strips and a number ofspaced, electrically conducting louvers resiliently mounted on thestrips and extending at an acute angle with respect thereto, said bodyadapted to be disposed between a pair of electrically conductingterminals movable toward and away from each other with the louvers beingengageable with the terminals; and a pair of spacers coupled with thebody and projecting laterally therefrom for limiting the movement of theterminals toward each other when the connector is disposed therebetween,one of the spacers being at the inner periphery of said body and theother spacer being at the outer periphery of the body, each spacerhaving a thickness greater than that of said strips but less than thenormal projected distance of the louvers laterally of the strips, eachspacer having a stepped portion engageable with a respective strip.
 8. Aconnector as set forth in claim 7, wherein said spacers are connected torespective strips.
 9. A connector as set forth in claim 7, wherein thespacers are separable from respective strips.